Abstract: A Rankine cycle for recovering waste heat from an engine includes a Rankine cycle circuit having a pump, a heat exchanger, an expansion device, a cooling device and a bypass circuit. The bypass circuit selectively provides a flow path for working fluid to bypass the expansion device, and includes a flow control valve actuated by a working fluid pressure differential to selectively open or close the bypass flow path. The expansion device includes a drive member directly coupled to a front end accessory drive (FEAD) of the engine such that a rotational speed of the expansion device is dictated by engine speed and the expansion device is free from separate speed control. The expansion device provides torque to the FEAD via the drive member when the system is in a waste heat recovery mode thereby reducing engine load and improving fuel economy.

Abstract: A Rankine cycle system and method is described and illustrated, and in some embodiments includes an expander, a pump, a condenser, and a receiver comprising a variable fluid volume at least partially defined by a movable member, wherein the variable fluid volume defines at least a portion of the working fluid flow path between the condenser and the inlet of the pump. Also, a method of charging a Rankine cycle system with working fluid is described and illustrated, and can include applying a regulated pressure to a chamber located within a receiver, introducing the working fluid to the Rankine cycle system, the working fluid being separated from the chamber by a movable member of the receiver, monitoring displacement of the movable member, and stopping the introduction of working fluid into the Rankine cycle system when the movable member reaches a predetermined position.

Abstract: The invention provides a solid oxide fuel cell system including a fuel cell stack having an anode side and a cathode side, an anode tailgas oxidizer for oxidizing an anode exhaust flow from the anode side to produce an oxidized anode exhaust flow, and a heat exchanger. The heat exchanger includes a first inlet for receiving a cathode exhaust flow from the cathode side of the fuel cell stack, a second inlet for receiving the oxidized anode exhaust flow, and a mixing region for combining the cathode exhaust flow and the oxidized anode exhaust flow to produce a combined exhaust flow. An air flow path for supplying air to the fuel cell stack to support an energy-producing reaction in the fuel cell stack extends through the heat exchanger so that heat is transferred from the combined exhaust flow to the air traveling along the air flow path.

Abstract: An integrated fuel cell unit (10) includes an annular array (12) of fuel cell stacks (14), an annular cathode recuperator (20), an annular anode recuperator (22), a reformer (24), and an anode exhaust cooler (26), all integrated within a common housing structure (28).

Abstract: The present invention provides, among other things, a method of operating a solid oxide fuel cell system including a fuel cell stack. The method can include the acts of combining an exhaust flow from an anode side of the fuel cell stack and an exhaust flow from a cathode side of the fuel cell stack, transferring heat from the combined exhaust flow to a first air flow, and combining a second air flow and the heated first air flow upstream from the fuel cell stack to control a temperature of the combined air flow entering the cathode side of the solid oxide fuel cell.

Abstract: The present invention provides, among other things, a method of operating a solid oxide fuel cell system including a fuel cell stack. The method can include the acts of combining an exhaust flow from an anode side of the fuel cell stack and an exhaust flow from a cathode side of the fuel cell stack, transferring heat from the combined exhaust flow to a first air flow, and combining a second air flow and the heated first air flow upstream from the fuel cell stack to control a temperature of the combined air flow entering the cathode side of the solid oxide fuel cell.

Abstract: A fuel cell unit includes a plurality of angularly spaced fuel cell stacks arranged to form a ring-shaped structure about a central axis, each of the fuel cell stacks having a stacking direction extending parallel to the central axis. The fuel cell unit also includes an annular cathode feed manifold surrounding the fuel cell stacks to deliver a cathode feed flow thereto, a plurality of baffles extending parallel to the central axis, each of the baffles located between an adjacent pair of the fuel cell stacks to direct a cathode feed flow from the annular cathode feed manifold and radially inwardly through the adjacent pair, and an annular cathode exhaust manifold surrounded by the fuel cell stacks to receive a cathode exhaust flow therefrom.

Abstract: Relates to a process and apparatus that improves the hydrogen production efficiency for small scale hydrogen production. According to one aspect, the process provides heat exchangers that are thermally integrated with the reaction steps such that heat generated by exothermic reactions, combustion and water gas shift, are arranged closely to the endothermic reaction, steam reformation, and heat sinks, cool natural gas, water and air, to minimize heat loss and maximize heat recovery. Effectively, this thermally integrated process eliminates excess piping throughout, reducing initial capital cost.

Abstract: A fuel cell unit includes a plurality of angularly spaced fuel cell stacks arranged to form a ring-shaped structure about a central axis, each of the fuel cell stacks having a stacking direction extending parallel to the central axis.

Abstract: An integrated fuel cell unit (10) includes an annular array (12) of fuel cell stacks (14), an annular cathode recuperator (20), an annular anode recuperator (22), a reformer (24), and an anode exhaust cooler (26), all integrated within a common housing structure (28).

Abstract: A catalytic reactor/heat exchange device (10) is provided for generating a catalytic reaction in a reaction fluid flow (12) and transferring heat to a cooling fluid flow (14). The device includes reaction flow channels (20) with turbulators (30) therein. The turbulators (30) include an initial portion (40) and a selected portion (34) that includes a catalytic layer or coating (36) to initiate the desired catalytic reaction at a location (38) located downstream from the initial portion (40). In some preferred forms, each of the selected portions (34) of the turbulators (30) include at least one downstream section (103, 120) wherein the heat transfer performance has been intentionally reduced to improve performance of the device (10) during start up conditions.

Abstract: A coolant conditioning system is provided for supplying a coolant flow to a fuel processing subsystem. The coolant conditioning system includes a coolant preheater to transfer heat from a reformate flow to the coolant flow, a heater to selectively add heat to the coolant flow in response to the coolant flow dropping below a minimum temperature, at least one outlet flow path to provide a portion of the coolant flow to at least one fuel processing subsystem, and a return flow path to return a remainder of the coolant flow to a storage tank. The coolant conditioning system is dynamically controllable to provide a portion of the coolant flow above a minimum temperature to reduce or prevent condensation of the reformate flow in selected components of the fuel processing subsystem that receive the portion of the coolant flow.

Abstract: An integrated steam reformer/combustor assembly (42) is provided for use in a fuel processor (20) that supplies a steam/fuel feed mix (34) to be reformed in the assembly and a combustor feed (40) to be combusted in the assembly (42). The assembly (42) includes a housing (44,58) defining first and second axially extending, concentric annular passages in heat transfer relation to each other; a first convoluted fin (46) located in the first passage to direct the feed mix therethrough, the first convoluted fin coated with a catalyst that induces a desired reaction in the feed mix; and a second convoluted fin (50) located in the second passage to direct the combustor feed therethrough, the second convoluted fin coated with a catalyst that induces a desired reaction in the combustor feed.

Abstract: A combustor preheater (94) is provided for use in a fuel processor (20) to preheat a combustor feed (40) by transferring heat from a post water-gas shift reformate flow (32) to the combustor feed (40). The combustor preheater (94) includes a housing (92) defining first and second axially extending, concentric annular passages in heat transfer relation to each other; a first convoluted fin (96) located in the first passage to direct the post water-gas shift reformate flow (32) therethrough and a second convoluted fin (98) located in the second passage to direct the combustor feed therethrough.

Abstract: A fuel processing system is provided wherein heat is transferred from a reformate flow (32) downstream from a water-gas shift (38) to both a) a combustor feed flow (40) that is supplied to a combustor (25); and b) a water flow (26) that is supplied to a reformer feed mix (34) for a steam reformer (28).

Abstract: A recuperative heat exchanger (36) is provided for use in a fuel processor (20), the heat exchanger (36) transferring heat from a fluid flow (34) at one stage of a fuel processing operation to the fluid flow (32) at another stage of the fuel processing operation. The heat exchanger (36) includes a housing (56) defining first and second axially extending, concentric annular passages in heat transfer relation to each other; a first convoluted fin (70) located in the first passage to direct the fluid flow therethrough; and a second convoluted fin (72) located in the second passage to direct the fluid flow therethrough.

Abstract: A hydrogen storage and release device (10) is provided for storing and releasing hydrogen from a metal hydride (30) contained in the device (10) based on heat transfer to or from a coolant flow provided through the device (10). The device (10) includes a housing (12) and a metal hydride containing a tube bundle located within the housing (12), with the exteriors (26) of the tubes (16) of the bundle (14) being reduced over a selected length to provide a free flow area for the coolant flow.

Abstract: Systems and methods for a temperature control loop in a vehicular engine compartment to concurrently cool at least two devices with a single fluid supply source when each device requires the cooling supply fluid to have a distinct temperature. The supply fluid, having a first temperature, can be simultaneously routed through a primary heat exchanger and a mixing valve. The primary heat exchanger cools the first temperature fluid to produce a second temperature fluid. The mixing valve controllably receives at least some of the first temperature fluid and some of the second temperature fluid discharged from the primary heat exchanger and mixes the respective fluids to produce a third temperature fluid. The second temperature fluid not diverted to the mixing valve is used to cool a first device located downstream of the primary heat exchanger. The third temperature fluid is used to cool a second device located downstream of the mixing valve.

Abstract: An integrated heat exchanger and muffler unit (50,120,140) is provided for transferring heat between a first fluid and a second fluid, and for muffling the noise of the first fluid. The unit includes a housing (52) including a first inlet (60) for the first fluid, a first outlet (62) for the first fluid, a second inlet (64) for the second fluid, and a second outlet (66) for the second fluid. The unit (50,120,140) further includes a resonator (76) in the housing (52) and connected between the first inlet and outlet (60,62) to muffle noise in the first fluid, and a heat exchanger core (11,122) in the housing (52) connected to the first and second inlets and outlets to transfer heat between the first and second fluids. In one embodiment, the heat exchanger core surrounds the resonator. In another embodiment, the resonator surrounds the heat exchanger core.

Abstract: An integrated fuel cell unit (10) includes an annular array (12) of fuel cell stacks (14), an annular cathode recuperator (20), an annular anode recuperator (22), a reformer (24), and an anode exhaust cooler (26), all integrated within a common housing structure (28).